Yamaha 2C HP

OWNER’S MANUAL

2C

6A1-28199-2N-E0

U6A12NE0.book Page 1 Monday, March 5, 2007 6:48 PM

Read this owner’s manual carefully before operating or working on youroutboard motor. Keep this manual onboard in a waterproof bag when boating.This manual should stay with the outboard motor if it is sold.


Important manual informationEMU25103

To the ownerThank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understanding ofthese simple instructions will help you obtainmaximum enjoyment from your new Yamaha.If you have any question about the operationor maintenance of your outboard motor,please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol means AT-TENTION! BECOME ALERT! YOUR SAFE-TY IS INVOLVED!

WARNINGEWM00780

Failure to follow WARNING instructionscould result in severe injury or death to themachine operator, a bystander, or a per-son inspecting or repairing the outboardmotor.

CAUTION:ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to theoutboard motor.

NOTE:A NOTE provides key information to makeprocedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current productinformation available at the time of printing,there may be minor discrepancies between

your machine and this manual. If there is anyquestion concerning this manual, please con-sult your Yamaha dealer.To ensure long product life, Yamaha recom-mends that you use the product and performthe specified periodic inspections and mainte-nance by correctly following the instructions inthe owner’s manual. Any damage resultingfrom neglect of these instructions is not cov-ered by warranty.Some countries have laws or regulations re-stricting users from taking the product out ofthe country where it was purchased, and itmay be impossible to register the product inthe destination country. Additionally, the war-ranty may not apply in certain regions. Whenplanning to take the product to another coun-try, consult the dealer where the product waspurchased for further information.If the product was purchased used, pleaseconsult your closest dealer for customer re-registration, and to be eligible for the specifiedservices.

NOTE:The 2CMH and the standard accessories areused as a base for the explanations and illus-trations in this manual. Therefore some itemsmay not apply to every model.

EMU25121

2COWNER’S MANUAL

©2007 by Yamaha Motor Co., Ltd.1st Edition, February 2007

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan


Table of contents

General information ..........................1Identification numbers record.......... 1

Outboard motor serial number ........... 1C-Tick label ..................................... 1Important labels............................... 1

Warning labels.................................... 1

Safety information.............................3Safety information ........................... 3

Rotating parts ..................................... 3Hot parts............................................. 3Electric shock ..................................... 3Engine shut-off cord ........................... 3Gasoline ............................................. 3Gasoline exposure and spills ............. 3Carbon monoxide ............................... 3Modifications ...................................... 3

Boating safety ................................. 4Alcohol and drugs............................... 4Personal flotation devices .................. 4People in the water............................. 4Passengers ........................................ 4Overloading ........................................ 4Avoid collisions................................... 4Weather.............................................. 5Passenger training ............................. 5Boating safety publications................. 5Laws and regulations ......................... 5

Basic requirements...........................6Fueling instructions ......................... 6

Gasoline ............................................. 6Engine oil............................................ 6

Installation requirements ................. 6Boat horsepower rating ...................... 6Mounting motor .................................. 6Propeller selection.............................. 7

Basic components ............................8Main components............................ 8

Fuel tank............................................. 8Fuel tank cap...................................... 9Air vent screw..................................... 9

Fuel cock ............................................ 9Tiller handle........................................ 9Throttle lever .................................... 10Throttle friction adjuster .................... 10Engine shut-off switch ...................... 10Engine stop button ........................... 10Choke knob ...................................... 11Manual starter handle....................... 11Steering friction adjuster................... 11Trim rod (tilt pin) ............................... 11Tilt support knob............................... 12

Operation ......................................... 13Installation..................................... 13

Mounting the outboard motor ........... 13Clamping the outboard motor ........... 14

Breaking in engine ........................ 15Gasoline and engine oil mixing

chart (25:1).................................... 15Procedure for pre-mixed models ...... 15

Pre-operation checks .................... 16Fuel .................................................. 16Oil ..................................................... 16Controls ............................................ 16Engine .............................................. 16

Filling fuel and engine oil .............. 16Filling fuel for built-in tank................. 16Gasoline and oil mixing (100:1) ........ 16

Operating engine .......................... 17Feeding fuel...................................... 17Starting engine ................................. 18

Warming up engine....................... 20Direct drive models........................... 20

Shifting .......................................... 20Forward ............................................ 20Reverse ............................................ 20

Stopping engine............................ 21Procedure......................................... 21

Trimming outboard motor.............. 21Adjusting trim angle for manual tilt

models .......................................... 22Adjusting boat trim............................ 22


Table of contents

Tilting up and down ....................... 23Procedure for tilting up

(manual tilt models)....................... 24Procedure for tilting down

(manual tilt models)....................... 24Cruising in other conditions........... 25

Maintenance..................................... 26Specifications ................................ 26Transporting and storing outboard

motor .......................................... 26Clamp screw mounting models ........ 27Storing outboard motor..................... 27Procedure......................................... 27Lubrication........................................ 28Cleaning the outboard motor............ 29Checking painted surface of motor... 29

Periodic maintenance.................... 29Replacement parts ........................... 29Maintenance chart............................ 30Greasing........................................... 31Cleaning and adjusting spark plug ... 31Checking fuel system ....................... 32Inspecting idling speed..................... 33Checking wiring and connectors ...... 33Exhaust leakage............................... 33Water leakage .................................. 33Checking propeller ........................... 33Removing propeller .......................... 34Installing propeller ............................ 34Changing gear oil ............................. 35Inspecting and replacing anode(s) ... 36Checking top cowling ....................... 36Coating the boat bottom................... 36

Trouble Recovery............................ 37Troubleshooting ............................ 37Temporary action in emergency.... 40

Impact damage................................. 40Starter will not operate ..................... 40Emergency starting engine............... 41

Treatment of submerged motor..... 42Procedure......................................... 42


General information

1

EMU25170

Identification numbers recordEMU31290

Outboard motor serial numberThe outboard motor serial number is stampedon the label attached to the upper part of theswivel bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

EMU25213

C-Tick labelEngines affixed with this label conform to cer-tain portion(s) of the Australian Radio Com-munications Act.

EMU25382

Important labelsEMU25395

Warning labels

EMU25401

Label

WARNINGEWM01260

� Be sure shift control is in neutral beforestarting engine. (except 2HP)

1. Outboard motor serial number location

1. C-Tick label location

ZMU01697


General information

2

� Do not touch or remove electrical partswhen starting or during operation.

� Keep hands, hair, and clothes away fromflywheel and other rotating parts whileengine is running.

EMU25441

Label

WARNINGEWM01311

LEAKING FUEL COULD CAUSE A FIRE.Before tilting up the engine or laying it onits side:� Turn the fuel cock to the “closed” posi-

tion.� Tighten the air-vent screw on the fuel

tank cap.


3

Safety informationEMU33620

Safety informationObserve these precautions at all times.EMU33630

Rotating partsHands, feet, hair, jewelry, clothing, PFDstraps, etc. can become entangled with inter-nal rotating parts of the engine, resulting in se-rious injury or death.Keep the top cowling in place whenever pos-sible. Do not remove or replace the cowlingwith the engine running.Only operate the engine with the cowling re-moved according to the specific instructions inthe manual. Keep hands, feet, hair, jewelry,clothing, PFD straps, etc. away from any ex-posed moving parts.EMU33640

Hot partsDuring and after operation, engine parts arehot enough to cause burns. Avoid touchingany parts under the top cowling until the en-gine has cooled.EMU33650

Electric shockDo not touch any electrical parts while startingor operating the engine. They can causeshock or electrocution.EMU33670

Engine shut-off cordAttach the engine shut-off cord so that the en-gine stops if the operator falls overboard orleaves the helm. This prevents the boat fromrunning away under power and leaving peo-ple stranded, or running over people or ob-jects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tear loose,or route the cord where it could become en-tangled, preventing it from functioning.

Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.EMU33810

GasolineGasoline and its vapors are highly flam-mable and explosive. Always, refuel accord-ing to the procedure on page 17 to reduce therisk of fire and explosion.EMU33820

Gasoline exposure and spillsTake care not to spill gasoline. If gasolinespills, wipe it up immediately with dry rags.Dispose of rags properly.If any gasoline spills onto your skin, immedi-ately wash with soap and water. Changeclothing if gasoline spills on it.If you swallow gasoline, inhale a lot of gaso-line vapor, or get gasoline in your eyes, getimmediate medical attention. Never siphonfuel by mouth.EMU33900

Carbon monoxideThis product emits exhaust gases which con-tain carbon monoxide, a colorless, odorlessgas which may cause brain damage or deathwhen inhaled. Symptoms include nausea,dizziness, and drowsiness. Keep cockpit andcabin areas well ventilated. Avoid blocking ex-haust outlets.EMU33780

ModificationsDo not attempt to modify this outboard motor.Modifications to your outboard motor may re-duce safety and reliability, and render the out-board unsafe or illegal to use.


Safety information

4

EMU33740

Boating safetyThis section includes a few of the many im-portant safety precautions that you should fol-low when boating.EMU33710

Alcohol and drugsNever operate after drinking alcohol or takingdrugs. Intoxication is one of the most commonfactors contributing to boating fatalities.EMU33720

Personal flotation devicesHave an approved personal flotation device(PFD) on board for every occupant. Yamaharecommends that you must wear a PFDwhenever boating. At a minimum, childrenand non-swimmers should always wearPFDs, and everyone should wear PFDs whenthere are potentially hazardous boating condi-tions.EMU33730

People in the waterAlways watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. When some-one is in the water near the boat, shift intoneutral and shut off the motor.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Shut off the enginewhen a person is in the water near you.EMU33750

PassengersConsult your boat manufacturer’s instructionsfor details about appropriate passenger loca-tions in your boat and be sure all passengersare positioned properly before acceleratingand when operating above an idle speed.Standing or sitting in non-designated loca-tions may result in being thrown either over-board or within the boat due to waves, wakes,or sudden changes in speed or direction.

Even when people are positioned properly,alert your passengers if you must make anyunusual maneuver. Always avoid jumpingwaves or wakes.EMU33760

OverloadingDo not overload the boat. Consult the boat ca-pacity plate or boat manufacturer for maxi-mum weight and number of passengers. Besure that weight is properly distributed ac-cording to the boat manufacturers instruc-tions. Overloading or incorrect weightdistribution can compromise the boats han-dling and lead to an accident, capsizing orswamping.EMU33770

Avoid collisionsScan constantly for people, objects, and oth-er boats. Be alert for conditions that limit yourvisibility or block your vision of others.Operate defensively at safe speeds andkeep a safe distance away from people, ob-jects, and other boats.� Do not follow directly behind other boats or

waterskiers.� Avoid sharp turns or other maneuvers that

make it hard for others to avoid you or un-derstand where you are going.

� Avoid areas with submerged objects orshallow water.

� Ride within your limits and avoid aggressivemaneuvers to reduce the risk of loss of con-trol, ejection, and collision.

� Take early action to avoid collisions. Re-member, boats do not have brakes, andstopping the engine or reducing throttle canreduce the ability to steer. If you are notsure that you can stop in time before hittingan obstacle, apply throttle and turn in anoth-er direction.


Safety information

5

EMU33790

WeatherStay informed about the weather. Checkweather forecasts before boating. Avoid boat-ing in hazardous weather.EMU33880

Passenger trainingMake sure at least one other passenger istrained to operate the boat in the event of anemergency.EMU33890

Boating safety publicationsBe informed about boating safety. Additionalpublications and information can be obtainedfrom many boating organizations.EMU33600

Laws and regulationsKnow the marine laws and regulations whereyou will be boating- and obey them. Severalsets of rules prevail according to geographiclocation, but all are basically the same as theInternational Rules of the Road.


Basic requirements

6

EMU31490

Fueling instructions

WARNINGEWM01490

GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!� Do not smoke when refueling, and keep

away from sparks, flames, or othersources of ignition.

� Stop engine before refueling.� Refuel in a well-ventilated area.� Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately withdry rags.

� Do not overfill the fuel tank.� Tighten the filler cap securely after refu-

eling.� If you should swallow some gasoline, in-

hale a lot of gasoline vapor, or get gaso-line in your eyes, get immediate medicalattention.

� If any gasoline spills onto your skin, im-mediately wash with soap and water.Change clothing if gasoline spills on it.

� Touch the fuel nozzle to the filler open-ing or funnel to help prevent electrostat-ic sparks.

CAUTION:ECM00010

Use only new clean gasoline which hasbeen stored in clean containers and is notcontaminated with water or foreign matter.

EMU33980

Gasoline

If knocking or pinging occurs, use a differentbrand of gasoline or premium unleaded fuel. Ifunleaded gasoline is not available, then pre-mium gasoline can be used.

GasoholThere are two types of gasohol: gasohol con-taining ethanol and that containing methanol.Gasohol containing ethanol can be used ifethanol content does not exceed 10% and thefuel meets minimum octane ratings. Yamahadoes not recommended gasohol containingmethanol because it can cause fuel systemdamage or engine performance problems.EMU25650

Engine oil

If the recommended engine oil is not avail-able, another 2-stroke engine oil with anNMMA-certified TC-W3 rating may be used.EMU33550

Installation requirementsEMU33560

Boat horsepower ratingBefore installing the outboard motor(s), con-firm that the total horsepower of your motor(s)does not exceed the boats maximum horse-power rating. See the boats capacity plate orcontact the manufacturer.

WARNINGEWM01560

Overpowering a boat can cause severe in-stability.

EMU33570

Mounting motorYour dealer or other person experienced inproper rigging should mount the motor usingcorrect equipment and complete rigging in-structions. For further information, see page13.

Recommended gasoline:Regular unleaded gasoline

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil


Basic requirements

7

WARNINGEWM01570

� Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control,or fire hazards.

� Because the motor is very heavy, spe-cial equipment and training is requiredto mount it safely.

EMU34190

Propeller selectionNext to selecting an outboard, choosing theright propeller is one of the most importantpurchasing decisions a boater can make. Thetype, size, and design of your propeller havea direct impact on acceleration, top speed,fuel economy, and even engine life. Yamahadesigns and manufactures propellers for ev-ery Yamaha outboard motor and every appli-cation.Your outboard motor came with a Yamahapropeller chosen to perform well over a rangeof applications, but there may be uses wherea different propeller would be more appropri-ate.Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, chose a larger pitch propellerfor a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, chose the propellerthat lets the engine run in the proper range foryour maximum load but remember that youmay need to reduce your throttle setting tostay within the recommended engine speedrange when carrying lighter loads.For instructions on propeller removal and in-stallation, see page 33.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

ZMU04604

-x1 2 3


Basic components

8

EMU2579B

Main components

NOTE:* May not be exactly as shown; also may not be included as standard equipment on all models.

2C

EMU25821

Fuel tankIf your model included a fuel tank, its partsand functions are as follows.

1. Air vent screw2. Fuel tank cap3. Top cowling4. Anti-cavitation plate5. Propeller6. Cooling water inlet7. Clamp bracket8. Clamp screw9. Tiller handle10.Fuel cock11.Manual starter handle12.Choke knob13.Engine stop button/Engine shut-off switch14.Trim rod15.Rope attachment16.Tilt support knob

17.Throttle lever


Basic components

9

EMU25850

Fuel tank capThis cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise.EMU25860

Air vent screwThis screw is on the fuel tank cap. To loosenthe screw, turn it counterclockwise.EMU25872

Fuel cockThe fuel cock turns on and off the supply offuel from the fuel tank to the engine.

EMU25881

CloseTo stop fuel flow to the engine, turn the leveror knob to close position.Always turn the lever or knob to close positionwhen the engine is not running.

EMU25891

OpenWith the lever/knob in this position, fuel flowsto the carburetor.Normal running is done with the lever/knob inthis position.

EMU25911

Tiller handleTo change direction, move the tiller handle tothe left or right as necessary.

1. Air vent screw2. Fuel tank cap

1. Fuel cock

1. Close position

1. Open position


Basic components

10

EMU25952

Throttle leverTo increase speed, push the lever upward.

EMU25981

Throttle friction adjusterAn adjustable friction device within the apronsrestricts movement of the throttle lever ac-cording to the operator’s preference.

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

WARNINGEWM01480

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the throttle lever, whichcould result in an accident.

EMU25991

Engine shut-off switchThe clip must be attached to the engine shut-off switch for the engine to run. The cordshould be attached to a secure place on the

operator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thecord will pull out the clip, stopping ignition tothe engine. This will prevent the boat fromrunning away under power.

WARNINGEWM00121

� Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg while operating.

� Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-venting it from functioning.

� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

NOTE:The engine cannot be started with the clip re-moved.

EMU26001

Engine stop buttonTo open the ignition circuit and stop the en-gine, push this button.

1. Clip2. Cord


Basic components

11

EMU26050

Choke knobTo supply the engine with the rich fuel mixturerequired to start, turn this knob counterclock-wise.

EMU26070

Manual starter handleTo start the engine, first gently pull the handleout until resistance is felt. From that position,then pull the handle straight out quickly tocrank the engine.

EMU26122

Steering friction adjusterA friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-justing screw or bolt is located on the swivelbracket.

To increase resistance, turn the adjusterclockwise.To decrease resistance, turn the adjustercounterclockwise.

WARNINGEWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in anaccident.

EMU26261

Trim rod (tilt pin)The position of the trim rod determines theminimum trim angle of the outboard motor inrelation to the transom.


Basic components

12

EMU26321

Tilt support knobTo keep the outboard motor in the tilted up po-sition, push the tilt support knob under theswivel bracket.

CAUTION:ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboard mo-tor could shake loose from the tilt supportand fall. If the motor cannot be trailered inthe normal running position, use an addi-tional support device to secure it in the tiltposition.


Operation

13

EMU26902

InstallationThe information presented in this section is in-tended as reference only. It is not possible toprovide complete instructions for every possi-ble boat and motor combination. Propermounting depends in part on experience andthe specific boat and motor combination.

WARNINGEWM01590

� Overpowering a boat could cause se-vere instability. Do not install an out-board motor with more horsepower thanthe maximum rating on the capacityplate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

� Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control,or fire hazards. For permanently mount-ed models, your dealer or other personexperienced in proper rigging shouldmount the motor.

EMU26911

Mounting the outboard motor

WARNINGEWM01720

Your dealer or other person experiencedin proper outboard motor mountingshould show you how to mount your out-board motor.

The outboard motor should be mounted sothat the boat is well balanced. Otherwise, theboat could be hard to steer. For single-engineboats, mount the outboard motor on the cen-terline (keel line) of the boat.

EMU26921

Mounting heightTo run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat and alevel 25 mm (1 in.) below it.

1. Center line (keel line)

ZMU017601

ZMU02011

0–25mm(0–1in.)


Operation

14

CAUTION:ECM01630

� During water testing, check the buoyan-cy of the boat, at rest, with its maximumload. Check that the static water level onthe exhaust housing is low enough toprevent water entry into the power headwhen water rises due to waves when theoutboard is not running.

� Incorrect engine height or obstructionsto the smooth flow of water (such as thedesign or condition of the boat, or ac-cessories such as transom ladders ordepth finder transducers) can create air-borne water spray while the boat iscruising. If the motor is operated contin-uously in the presence of airborne waterspray, enough water could enter the en-gine through the intake opening on thecowling to cause severe engine dam-age. Eliminate the cause of the airbornewater spray.

NOTE:� The optimum mounting height of the out-

board motor is affected by the boat and mo-tor combination and the desired use. Testruns at different heights can help determinethe optimum mounting height. Consult yourYamaha dealer or boat manufacturer forfurther information on determining the prop-er mounting height.

� For instructions on setting the trim angle ofthe outboard motor, see page 21.

EMU26970

Clamping the outboard motor1. Place the outboard motor on the transom

so that it is positioned as close to the cen-ter as possible. Tighten the transomclamp screws evenly and securely. Oc-casionally check the clamp screws for

tightness during operation of the out-board motor because they could becomeloose due to engine vibration.

WARNINGEWM00640

Loose clamp screws could allow the out-board motor to fall off or move on the tran-som. This could cause loss of control andserious injury. Make sure the transomscrews are tightened securely. Occasion-ally check the screws for tightness duringoperation.

2. If the engine restraint cable attachment isequipped on your engine, an engine re-straint cable or chain should be used. At-tach one end to the engine restraint cableattachment and the other to a securemounting point on the boat. Otherwisethe engine could be completely lost if itaccidentally falls off the transom.

ZMU02012

ZMU02013


Operation

15

3. Secure the clamp bracket to the transomusing the bolts provided with the out-board (if packed). For details, consultyour Yamaha dealer.

WARNINGEWM00650

Avoid using bolts, nuts or washers otherthan those contained in the engine pack-aging. If used, they must be of at least thesame quality of material and strength andmust be tightened securely. After tighten-ing, test run the engine and check theirtightness.

EMU30173

Breaking in engineYour new engine requires a period of break-into allow mating surfaces of moving parts towear in evenly. Correct break-in will help en-sure proper performance and longer enginelife.

CAUTION:ECM00800

Failure to follow the break-in procedurecould result in reduced engine life or evensevere engine damage.

EMU27050

Gasoline and engine oil mixing chart (25:1)

CAUTION:ECM00150

Be sure to mix gasoline and oil complete-ly, otherwise the engine may be damaged.

EMU27074

Procedure for pre-mixed modelsRun the engine under load (in gear with a pro-peller installed) for 10 hours as follows.1. First 10 minutes:

Run the engine at the lowest possiblespeed. A fast idle in neutral is best.

2. Next 50 minutes:Do not exceed half throttle (approximate-ly 3000 r/min). Vary engine speed occa-sionally. If you have an easy-planingboat, accelerate at full throttle onto plane,then immediately reduce the throttle to3000 r/min or less.

3. Next two hours:Accelerate at full throttle onto plane, thenreduce engine speed to three-quarterthrottle (approximately 4000 r/min). Varyengine speed occasionally. Run at fullthrottle for one minute, then allow about10 minutes of operation at three-quarterthrottle or less to let the engine cool.

4. Remaining seven hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

5. After the first 10 hours:Operate the engine normally. Use thestandard premix ratio of gasoline and oil.For details on mixing fuel and oil, seepage 16.

1. : Gasoline2. : Engine oil


Operation

16

EMU27104

Pre-operation checks

WARNINGEWM00081

If any item in the pre-operation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise an accident couldoccur.

CAUTION:ECM00120

Do not start the engine out of water. Over-heating and serious engine damage canoccur.

EMU31500

Fuel� Check to be sure you have plenty of fuel for

your trip.� Make sure there are no fuel leaks or gaso-

line fumes.EMU27120

Oil� Check to be sure you have plenty of oil for

your trip.EMU27130

Controls� Check throttle, shift, and steering for proper

operation before starting the engine.� The controls should work smoothly, without

binding or unusual free play.� Look for loose or damaged connections.� Check operation of the starter and stop

switches when the outboard motor is in thewater.

EMU27140

Engine� Check the engine and engine mounting.� Look for loose or damaged fasteners.� Check the propeller for damage.

EMU27233

Filling fuel and engine oilEMU27253

Filling fuel for built-in tank

WARNINGEWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other sourc-es of ignition.

1. With the outboard motor tilted down (inthe vertical running position), remove thefuel tank cap.

2. Use a funnel if the nozzle on the fuel canor pump is not small enough or longenough to fit into the mouth of the fueltank.

3. Fill the fuel tank carefully.4. Securely close the cap after refueling.

Wipe up any spilled fuel.

EMU27405

Gasoline and oil mixing (100:1)

Fuel tank capacity:1.2 L (0.32 US gal) (0.26 Imp.gal)

Gasoline to engine oil ratio

Break-in period See page 15

After break-in 100:1

1. : Gasoline2. : Engine oil

100:11 L

(0.26 US gal, 0.22 Imp gal)

12 L


14 L


24 L


0.01 L

(0.01 US qt, 0.01 Imp qt)

0.12 L

(0.13 US qt, 0.11 Imp qt)

0.14 L

(0.15 US qt, 0.12 Imp qt)

0.24 L

(0.25 US qt, 0.21 Imp qt)

ZMU04910


Operation

17

If equipped with a portable fuel tank1. Pour oil into the portable fuel tank, and

then add gasoline.2. Replace the fuel tank cap and close tight-

ly.3. Shake the fuel tank to mix the fuel thor-

oughly.4. Make sure that the oil and gasoline are

mixed.If equipped with a built-in fuel tank1. Pour oil into a clean fuel can, and then

add gasoline.

2. Replace the fuel can cap and close tight-ly.

3. Shake the fuel can to mix the fuel thor-oughly.

4. Make sure that the oil and gasoline aremixed.

5. Pour the gasoline and oil mixture into thebuilt-in fuel tank.

CAUTION:ECM00811

� Avoid using any oil other than the spec-ified type.

� Use a thoroughly blended fuel-oil mix-ture.

� If the mixture is not thoroughly mixed, orif the mixing ratio is incorrect, the fol-lowing problems could occur.

� Low oil ratio: Lack of oil could cause ma-jor engine trouble, such as piston sei-zure.

� High oil ratio: Too much oil could causefouled spark plugs, smoky exhaust, andheavy carbon deposits.

NOTE:If using a permanently installed tank, pour theoil gradually as the gasoline is being added tothe tank.

EMU27450

Operating engineEMU31510

Feeding fuel

WARNINGEWM00420

� Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

� When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while looseningthe air vent screw.

� This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which could cause braindamage or death when inhaled. Symp-

1. Engine oil2. Gasoline


Operation

18

toms include nausea, dizziness, anddrowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets.

1. Loosen the air vent screw on the fuel tankcap by one turn.

2. Open the fuel cock.

EMU27491

Starting engine

WARNINGEWM01600

Before starting the engine, make sure thatthe boat is tightly moored and that you cansteer clear of any obstructions. Be surethere are no swimmers in the water nearyou.

EMU27512

Manual start models1. If the engine shut-off cord is equipped, at-

tach it to a secure place on your clothing,or your arm or leg. Then install the clip onthe other end of the cord into the engineshut-off switch.

WARNINGEWM00121

� Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg while operating.


� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

2. Place the throttle lever in the start posi-tion.

WARNINGEWM00100

The propeller rotates whenever the engineis running. Do not move the throttle con-trol lever from the start position during


Operation

19

warm-up. The boat could unexpectedlystart to move, which could result in an ac-cident.

3. Place the choke knob in the start position.After the engine starts, return the knob tothe home position.

NOTE:� It is not necessary to use the choke when

starting a warm engine.� If the choke knob is left in the start position

while the engine is running, the engine willrun poorly or stall.

4. Pull the manual starter handle slowly untilyou feel resistance. Then give a strongpull straight out to start the engine. Re-peat if necessary.

5. After the engine starts, slowly return themanual starter handle to the original posi-tion before releasing it.

6. Place the throttle control lever slowly tothe fully closed position.

NOTE:� When the engine is cold, it needs to be

warmed up. For further information, seepage 20.

� If the engine does not start on the first try,repeat the procedure. If the engine fails tostart after 4 or 5 tries, open the throttle asmall amount (between 1/8 and 1/4) and tryagain. Also if the engine is warm and fails tostart, open the throttle a same amount andtry to start the engine again. If the enginestill fails to start, see page 37.


Operation

20

EMU27670

Warming up engineEMU27692

Direct drive models

WARNINGEWM00100

The propeller rotates whenever the engineis running. Do not move the throttle con-trol lever from the start position duringwarm-up. The boat could unexpectedlystart to move, which could result in an ac-cident.

1. Before beginning operation, allow the en-gine to warm up at idle speed for 3 min-utes. Failure to do this will shorten enginelife.

2. Check for a steady flow of water from thecooling water pilot hole.

CAUTION:ECM00511

A continuous flow of water from the cool-ing water pilot hole shows that the waterpump is pumping water through the cool-ing passages. If water is not flowing out ofthe hole at all times while the engine isrunning, overheating and serious damagecould occur. Stop the engine and checkwhether the cooling water inlet on the low-er case or the cooling water pilot hole isblocked. Consult your Yamaha dealer ifthe problem cannot be located and cor-rected.

EMU27740

Shifting

WARNINGEWM00180

Before shifting, make sure there are noswimmers or obstacles in the water nearyou.

CAUTION:ECM00220

To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the en-gine idles (or runs at low speeds).

EMU27750

ForwardWhen the engine is started, the propellerturns and the boat begins to move forward.EMU27770

Reverse

WARNINGEWM00190

When operating in reverse, go slowly. Donot open the throttle more than half. Other-wise the boat could become unstable,which could result in loss of control andan accident.

These models can turn a full 360° in its brack-et (full-pivot system). To back up the boat,simply turn the engine around 180° with thetiller handle facing toward you.


Operation

21

EMU27820

Stopping engineBefore stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operating athigh speed is not recommended.EMU31521

Procedure1. Push and hold the engine stop button un-

til the engine comes to a complete stop.

2. After stopping the engine, tighten the airvent screw on the fuel tank cap and setthe fuel cock to the closed position.

NOTE:The engine can also be stopped by pulling thecord and removing the clip from the engineshut-off switch.

EMU27861

Trimming outboard motorThe trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trim an-gle depends upon the combination of boat,engine, and propeller. Correct trim is also af-fected by variables such as the load in theboat, sea conditions, and running speed.

WARNINGEWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can make steer-ing the boat more difficult. This increasesthe possibility of an accident. If the boatbegins to feel unstable or is hard to steer,slow down and/or readjust the trim angle.


Operation

22

EMU27872

Adjusting trim angle for manual tilt modelsThere are 4 or 5 holes provided in the clampbracket to adjust the outboard motor trim an-gle.1. Stop the engine.2. Tilt the outboard motor up, and then re-

move the trim rod from the clamp bracket.

3. Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rodaway from the transom.To lower the bow (“trim-in”), move the rod to-ward the transom.Make test runs with the trim set to different an-gles to find the position that works best foryour boat and operating conditions.

WARNINGEWM00400

� Stop the engine before adjusting thetrim angle.

� Use care to avoid being pinched whenremoving or installing the rod.

� Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabilityor control problems. Improper trim an-gle can cause loss of control.

NOTE:The outboard motor trim angle can bechanged approximately 4 degrees by shiftingthe trim rod one hole.

EMU27911

Adjusting boat trimWhen the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start onto plane.

1. Trim operating angle

1. Trim rod

ZMU02043

1


Operation

23

Bow UpToo much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is more airdrag. Excessive trim-out can also cause thepropeller to ventilate, which reduces perfor-mance further, and the boat may “porpoise”(hop in the water), which could throw the op-erator and passengers overboard.

Bow DownToo much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Operat-ing with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

NOTE:Depending on the type of boat, the outboardmotor trim angle may have little effect on thetrim of the boat when operating.

EMU27922

Tilting up and downIf the engine will be stopped for some time orif the boat is moored in shallows, the outboardmotor should be tilted up to protect the propel-ler and lower casing from damage by collisionwith obstructions, and also to reduce salt cor-rosion.

WARNINGEWM00221

Be sure all people are clear of the out-board motor when tilting up and down,Body parts can be crushed between themotor and the clamp bracket when the mo-tor is trimmed or tilted.

WARNINGEWM00230

Leaking fuel is a fire hazard. Tighten theair vent screw and place the fuel cock inthe closed position if the outboard motorwill be tilted for more than a few minutes.Otherwise fuel may leak.


Operation

24

CAUTION:ECM00231

� Before tilting the outboard motor, followthe procedure under “Stopping engine”in this chapter. Never tilt the outboardmotor while the engine is running. Se-vere damage from overheating can re-sult.

� Do not tilt up the engine by pushing thetiller handle because this could breakthe handle.

� Keep the power unit higher than the pro-peller at all times. Otherwise water couldrun into the cylinder and cause damage.

� The outboard motor cannot be tiltedwhen in reverse or when the outboardmotor is turned 180° (facing the rear).

EMU27964

Procedure for tilting up (manual tilt models)1. Place the gear shift lever in neutral (if

equipped) and face the outboard motorforward.

2. On full-pivot system models, tighten thesteering friction adjuster by turning itclockwise to prevent the motor from turn-ing freely.

3. Tighten the air vent screw. On modelsequipped with a fuel joint, disconnect thefuel line from the outboard motor.

4. Close the fuel cock.5. Tilt support bar equipped models: Hold

the rear of the top cowling or the rear han-dle (if equipped) with one hand and tilt theoutboard motor up fully until the tilt sup-port bar automatically locks.

6. Tilt support knob equipped models: Holdthe rear of the top cowling with one hand,fully tilt the outboard motor up, and pushthe tilt support knob into the clamp brack-et.

7. Tilt support lever equipped models: Holdthe rear handle and tilt the engine up fullyuntil the tilt support lever automaticallylocks.

NOTE:Tilt support lever/bar equipped models: If themotor is not facing forward, the tilt support le-ver/bar cannot automatically turn to thelocked position. If the tilt support lever/bardoes not automatically lock, swing the motora little to the left and right.

EMU28032

Procedure for tilting down (manual tilt models)1. Slightly tilt the outboard motor up.2. If equipped with the tilt support bar: Slow-

ly tilt the outboard motor down while pull-ing the tilt support bar lever up.

3. If equipped with the tilt support knob: Pullthe knob out, and then slowly tilt the out-board motor down.


Operation

25

4. If equipped with the tilt support lever:Slowly tilt the outboard motor down whilepulling the tilt support lever up.

5. Loosen the steering friction adjuster byturning it counterclockwise, and adjustthe steering friction according to operatorpreference.

WARNINGEWM00720

If there is too much resistance it could bedifficult to steer, which could result in anaccident.

EMU28193

Cruising in other conditionsCruising in salt waterAfter operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh waterand, if possible, rinse the power head underthe cowling.Cruising in muddy or turbid waterYamaha strongly recommends that you usethe optional chromium-plated water pump kit(available for V4 and large engines) if you usethe outboard motor in water with a lot of sedi-ment in it, such as muddy or other turbid(cloudy) water.Cruising in acidic waterWater in some areas can be acidic. After op-erating in such water, flush the cooling pas-sages with fresh water to prevent corrosion.Also rinse the outside of the outboard motorwith fresh water.


Maintenance

26

EMU31480

Specifications

NOTE:“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”for plastic propeller installed.

EMU28219

Dimension:Overall length:

603 mm (23.7 in)Overall width:

240 mm (9.4 in)Overall height S:

916 mm (36.1 in)Transom height S:

417 mm (16.4 in)Weight (PL) S:

9.8 kg (22 lb)Performance:

Full throttle operating range:4000–5000 r/min

Maximum output:1.5 kW@4500 r/min (2 HP@4500 r/min)

Idling speed (in neutral):1150 ±50 r/min

Engine:Type:

2-stroke SDisplacement:

50.0 cm³Bore × stroke:

42.0 × 36.0 mm (1.65 × 1.42 in)Ignition system:

CDISpark plug (NGK):

BR7HSSpark plug gap:

0.6–0.7 mm (0.024–0.028 in)Control system:

TillerStarting system:

Manual

Starting carburetion system:Choke valve

Drive unit:Gear positions:

ForwardGear ratio:

2.08 (27/13)Trim and tilt system:

Manual tiltPropeller mark:

AFuel and oil:

Recommended fuel:Regular unleaded gasoline

Fuel tank capacity (built in type):1.2 L (0.32 US gal) (0.26 Imp.gal)

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil

Fuel:oil ratio:Regular gasoline:

100 :1Lubrication:

Pre-mixed fuel and oilRecommended gear oil:

Hypoid gear oil SAE#90Gear oil quantity:

45.0 cm³ (1.52 US oz) (1.59 Imp.oz)Tightening torque for engine:

Spark plug:25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

EMU28223

Transporting and storing out-board motor

WARNINGEWM00690

� Leaking fuel is a fire hazard. When trans-porting and storing the outboard motor,close the air vent screw and fuel cock toprevent fuel from leaking.

� USE CARE when transporting fuel tank,whether in a boat or car.

� DO NOT fill fuel container to maximumcapacity. Gasoline will expand consider-ably as it warms up and can build up


Maintenance

27

pressure in the fuel container. This cancause fuel leakage and a potential firehazard.

WARNINGEWM00700

Never get under the lower unit while it istilted, even if a motor support bar is used.Severe injury could occur if the outboardmotor accidentally falls.

CAUTION:ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboard mo-tor could shake loose from the tilt supportand fall. If the motor cannot be trailered inthe normal running position, use an addi-tional support device to secure it in the tiltposition.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt posi-tion using a motor support device such as atransom saver bar. Consult your Yamahadealer for further details.EMU28235

Clamp screw mounting modelsWhen transporting or storing the outboardmotor while removed from a boat, keep theoutboard motor in the attitude shown.

NOTE:Place a towel or something similar under theoutboard motor to protect it from damage.

EMU30272

Storing outboard motorWhen storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealer pri-or to storage. However, you, the owner, with aminimum of tools, can perform the followingprocedures.

CAUTION:ECM01411

� Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder through theexhaust port and cause engine trouble.

� Store the outboard motor in a dry, well-ventilated place, not in direct sunlight.

EMU28303

ProcedureEMU28313

Flushing in a water tank1. Wash the outboard motor body using

fresh water. For further information, seepage 29.

ZMU02870


Maintenance

28

2. Place the fuel cock in the closed positionand disconnect the fuel line if equipped.Tighten the air vent screw, if equipped.

3. Remove the engine top cowling and si-lencer cover.

4. Install the outboard motor on the testtank.

5. Fill the tank with fresh water to above thelevel of the anti-cavitation plate.

CAUTION:ECM00290

If the fresh water level is below the level ofthe anti-cavitation plate, or if the watersupply is insufficient, engine seizure mayoccur.

6. Cooling system flushing is essential toprevent the cooling system from cloggingup with salt, sand, or dirt. In addition, fog-ging/lubricating of the engine is mandato-ry to prevent excessive engine damagedue to rust. Perform the flushing and fog-ging at the same time.

WARNINGEWM00090


� Keep hands, hair, and clothes away fromthe flywheel and other rotating partswhile the engine is running.

7. Run the engine at a fast idle for a fewminutes in neutral position.

8. Just prior to turning off the engine, quicklyspray “Fogging Oil” alternately into eachcarburetor or the fogging hole of the si-lencer cover, if equipped. When properlydone, the engine will smoke excessivelyand almost stall.

9. If “Fogging Oil” is not available, run theengine at a fast idle until the fuel systemempties and the engine stops.

10. Remove the outboard motor from the testtank.

11. Install the silencer cover or fogging holecap, and the top cowling.

12. Drain the cooling water completely out ofthe motor. Clean the body thoroughly.

13. If “Fogging Oil” is not available, removethe spark plug(s). Pour a teaspoonful ofclean engine oil into each cylinder. Crankseveral times manually. Replace thespark plug(s).

14. Drain the fuel from both the built-in andportable fuel tanks, on equipped models.

NOTE:Portable fuel tank equipped models: Store theportable fuel tank in a dry, well-ventilatedplace, not in direct sunlight.

EMU28402

Lubrication1. Install the spark plug(s) and torque to

proper specification. For information onspark plug installation, see page 31.

1. Water surface2. Lowest water level


Maintenance

29

2. Change the gear oil. For instructions, seepage 35. Inspect the oil for the presenceof water that indicates a leaky seal. Sealreplacement should be performed by anauthorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de-tails, see page 31.

NOTE:For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about foggingoil and procedures for your engine.

EMU28450

Cleaning the outboard motorAfter use, wash the exterior of the outboardmotor with fresh water. Flush the cooling sys-tem with fresh water.

NOTE:For cooling system flushing instructions, seepage 26.

EMU28460

Checking painted surface of motorCheck the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint are morelikely to corrode. If necessary, clean and paintthe areas. A touch-up paint is available fromyour Yamaha dealer.

EMU28478

Periodic maintenance

WARNINGEWM01071

Be sure to turn off the engine when youperform maintenance unless otherwisespecified. If you are not familiar with ma-chine servicing, this work should be doneby your Yamaha dealer or other qualifiedmechanic.

EMU28511

Replacement partsIf replacement parts are necessary, use onlygenuine Yamaha parts or parts of equivalentdesign and quality. Any part of inferior qualitymay malfunction, and the resulting loss ofcontrol could endanger the operator and pas-sengers. Yamaha genuine parts and acces-sories are available from your Yamahadealer.


Maintenance

30

EMU28522

Maintenance chartFrequency of maintenance operations may be adjusted according to the operating conditions,but the following table gives general guidelines. Refer to the sections in this chapter for expla-nations of each owner-specific action.

NOTE:When operating in salt water, turbid or muddy water, the engine should be flushed with cleanwater after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

10 hours (1 month)

50 hours (3 months)

100 hours (6 months)

200 hours (1 year)

Anode(s) (external) Inspection / replace-ment

Cooling water passag-es Cleaning

Cowling clamp Inspection

Fuel filter (inside built-in fuel tank) Inspection / cleaning

Fuel system Inspection

Fuel tank (built-in tank) Inspection / cleaning

Gear oil Change

Greasing points Greasing

Idling speed (carbure-tor models) Inspection

Propeller and cotter pin Inspection / replace-ment

Thermostat Inspection / replace-ment

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Water pump Inspection / replace-ment

Spark plug(s) Cleaning / adjustment / replacement


Maintenance

31

EMU28941

GreasingYamaha grease A (water resistant grease)Yamaha grease D (corrosion resistant grease; for propeller shaft)2C

EMU28953

Cleaning and adjusting spark plug

WARNINGEWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow externalsparks, which could lead to explosion orfire.

WARNINGEWM01550

The engine will still be very hot when it hasjust been turned off. Take extremely careso that neither you nor anyone else getsburnt. To avoid burns, work on the enginewhen it has cooled down.


Maintenance

32

The spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate something aboutthe condition of the engine. For example, if thecenter electrode porcelain is very white, thiscould indicate an intake air leak or carburetionproblem in that cylinder. Do not attempt to di-agnose any problems yourself. Instead, takethe outboard motor to a Yamaha dealer. Youshould periodically remove and inspect thespark plug because heat and deposits willcause the spark plug to slowly break downand erode. If electrode erosion becomes ex-cessive, or if carbon and other deposits areexcessive, you should replace the spark plugwith another of the correct type.

Before fitting the spark plug, measure theelectrode gap with a wire thickness gauge;adjust the gap to specification if necessary.

When fitting the plug, always clean the gasketsurface and use a new gasket. Wipe off anydirt from the threads and screw in the sparkplug to the correct torque.

NOTE:If a torque-wrench is not available when youare fitting a spark plug, a good estimate of thecorrect torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the cor-rect torque as soon as possible with a torque-wrench.

EMU28962

Checking fuel system

WARNINGEWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other sourc-es of ignition.

WARNINGEWM00910

Leaking fuel can result in fire or explosion.� Check for fuel leakage regularly.� If any fuel leakage is found, the fuel sys-

tem must be repaired by a qualified me-chanic. Improper repairs can make theoutboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-function. If a problem is found, your Yamahadealer or other qualified mechanic should re-pair it immediately.

Standard spark plug:BR7HS

1. Spark plug gap2. Spark plug part number3. Spark plug I.D. mark (NGK)

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Spark plug torque:25.0 Nm (18.4 ft-lb) (2.55 kgf-m)


Maintenance

33

Checkpoints� Fuel system parts leakage� Fuel line joint leakage� Fuel line cracks or other damage� Fuel connector leakageEMU30810

Inspecting idling speed

WARNINGEWM01440


� Keep hands, hair, and clothes away fromthe flywheel and other rotating partswhile the engine is running.

� The propeller rotates whenever the en-gine is running. Do not move the throttlecontrol lever from the start position dur-ing warm-up. The boat could unexpect-edly start to move, which could result inan accident.

CAUTION:ECM01520

This procedure must be performed whilethe outboard motor is in the water. A testtank can be used.

A diagnostic tachometer should be used forthis procedure. Results may vary dependingon whether testing is conducted with theflushing attachment, in a test tank, or with theoutboard motor in the water.

1. Start the engine and allow it to warm upfully with the throttle in the start position orless until it is running smoothly. If the out-board is mounted on a boat, be sure theboat is tightly moored.

NOTE:Correct idling speed inspection is only possi-ble if the engine is fully warmed up. If notwarmed up fully, the idle speed will measurehigher than normal. If you have difficulty veri-fying the idle speed, or the idle speed requiresadjustment, consult a Yamaha dealer or otherqualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 26.

EMU29112

Checking wiring and connectors� Check that each grounding wire is properly

secured.� Check that each connector is engaged se-

curely.EMU29120

Exhaust leakageStart the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.EMU29130

Water leakageStart the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.EMU32120

Checking propeller

WARNINGEWM01610

You could be seriously injured if the en-gine accidentally starts when you are nearthe propeller.� Before inspecting, removing, or install-

ing the propeller, remove the spark plugcaps from the spark plugs. Also, place


Maintenance

34

the shift control in neutral, turn the mainswitch to “ ” (off) and remove the key,and remove the cord from the engineshut-off switch. Turn off the battery cut-off switch if your boat has one.

� Do not use your hand to hold the propel-ler when loosening or tightening thepropeller nut. Put a wood block betweenthe anti-cavitation plate and the propel-ler to prevent the propeller from turning.

Checkpoints� Check each of the propeller blades for

wear, erosion from cavitation or ventilation,or other damage.

� Check the propeller shaft for damage.� Check the shear pin for wear or damage.� Check for fish line tangled around the pro-

peller shaft.

� Check the propeller shaft oil seal for dam-age.

NOTE:It is designed to break if the propeller hits ahard underwater obstacle to help protect thepropeller and drive mechanism. The propellerwill then spin freely on the shaft. If this hap-pens, the shear pin must be replaced.

EMU30661

Removing propellerEMU29181

Shear pin models1. Straighten the cotter pin and pull it out us-

ing a pair of pliers.

2. Remove the propeller nut and washer, ifequipped.

3. Remove the shear pin and the propeller.EMU30671

Installing propellerEMU29221

Shear pin models

CAUTION:ECM00500

Be sure to use a new cotter pin and bendthe ends over securely. Otherwise the pro-peller could come off during operation andbe lost.

1. Apply Yamaha marine grease or corro-sion resistant grease to the propellershaft.

ZMU01896

1. Cotter pin2. Propeller3. Shear pin


Maintenance

35

2. Insert the shear pin into the hole in thepropeller shaft.

3. Align the shear pin with the groove in thepropeller boss, and slide the propellerover the propeller shaft.

4. Align the hole in the propeller with the re-cess in the propeller shaft. Insert a newcotter pin in the hole and bend the cotterpin ends.

NOTE:There is a holder on the steering handle forspare shear and cotter pins. Be sure to re-place a pin in the holder if one is used.

EMU29282

Changing gear oil

WARNINGEWM00800

� Be sure the outboard motor is securelyfastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

� Never get under the lower unit while it istilted, even when the tilt support lever orknob is locked. Severe injury could oc-cur if the outboard motor accidentallyfalls.

1. Tilt the outboard motor so that the gear oildrain screw is at the lowest point possi-ble.

2. Place a suitable container under the gearcase.

3. Remove the gear oil drain screw and gas-ket.

NOTE:� If a magnetic gear oil drain screw is

equipped, remove all metal particles fromthe screw before installing it.

� Always use new gaskets. Do not reuse theremoved gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.

CAUTION:ECM00710

Inspect the used oil after it has beendrained. If the oil is milky, water is gettinginto the gear case which can cause geardamage. Consult a Yamaha dealer for re-pair of the lower unit seals.

NOTE:For disposal of used oil, consult your Yamahadealer.

5. With the outboard motor in a vertical po-sition, and using a flexible or pressurizedfilling device, inject the gear oil into thegear oil drain screw hole.

1. Gear oil drain screw2. Oil level plug

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:45.0 cm³ (1.52 US oz) (1.59 Imp.oz)


Maintenance

36

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oildrain screw.

EMU29312

Inspecting and replacing anode(s)Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

CAUTION:ECM00720

Do not paint anodes, as this would renderthem ineffective.

NOTE:Inspect ground leads attached to external an-odes on equipped models. Consult a Yamahadealer for inspection and replacement of inter-nal anodes attached to the power unit.

EMU29391

Checking top cowling

CAUTION:ECM01650

Be sure the cowling is closed securely andthat there are no gaps. A loose or improp-erly fitting cover could allow water into theengine.

Check the fitting of the top cowling by pushingit with both hands. If it is loose have it repairedby your Yamaha dealer.EMU29400

Coating the boat bottomA clean hull improves boat performance. Theboat bottom should be kept as clean of marinegrowth as possible. If necessary, the boat bot-tom can be coated with an anti-fouling paintapproved for your area to inhibit marinegrowth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.


Trouble Recovery

37

EMU29425

TroubleshootingA problem in the fuel, compression, or ignitionsystems can cause poor starting, loss of pow-er, or other problems. This section describesbasic checks and possible remedies, and cov-ers all Yamaha outboard motors. Thereforesome items may not apply to your model.If your outboard motor requires repair, bring itto your Yamaha dealer.If the engine trouble-warning indicator isflashing, consult your Yamaha dealer.

Starter will not operate.Q. Is battery capacity weak or low?A. Check battery condition. Use battery of rec-ommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. Replace fuse with one of correct am-perage.

Q. Are starter components faulty?A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?A. Shift to neutral.

Engine will not start (starter operates).Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is starting procedure incorrect?A. See page 18.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Are spark plug cap(s) fitted incorrectly?A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tighten allloose connections. Replace worn or brokenwires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord not attached?A. Attach cord.

Q. Are engine inner parts damaged?A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Is fuel system obstructed?


Trouble Recovery

38

A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Is specified engine oil not being used?A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position.

Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle valve adjustment incorrect?A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected?A. Connect securely.

Warning buzzer sounds or indicator lights.Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorated?A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-tioned?A. Have serviced by a Yamaha dealer.


Trouble Recovery

39

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup?A. Drain filter cup.

Engine power loss.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate outboardat its recommended speed (r/min) range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Are weeds or other foreign matter tangledon gear housing?

A. Remove foreign matter and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Have electrical parts failed?A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?


Trouble Recovery

40

A. Connect correctly.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shiftlever position?A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangledon propeller?A. Remove and clean propeller.

Q. Is motor mounting bolt loose?A. Tighten bolt.

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.EMU29433

Temporary action in emergencyEMU29440

Impact damage

WARNINGEWM00870

The outboard motor can be seriously dam-aged by a collision while operating ortrailering. Damage could make the out-board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all compo-

nents for damage. Also inspect the boatfor damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU31311

Starter will not operateIf the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started with an emer-gency starter rope.

WARNINGEWM01461

� Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

� Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg while operating the boat.


� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steering


Trouble Recovery

41

control. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

� Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injure some-one.

� An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting the en-gine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

� Do not touch the ignition coil, spark plugwire, spark plug cap, or other electricalcomponents when starting or operatingthe motor. You could get an electricalshock.

� Do not move the throttle lever above thestart position when starting the engine.Because the propeller rotates wheneverthe engine is running, the boat could un-expectedly start to move, which couldresult in an accident.

EMU29550

Emergency starting engine1. Remove the spark plug cap cover by re-

moving the two screws.

2. Remove the aprons by removing theeight screws.

3. Remove the starter mechanism by re-moving the three bolts.

4. Prepare the engine for starting. For fur-ther information, see page 18.

5. Insert the knotted end of the rope into thenotch in the flywheel rotor and wind therope several turns around the flywheelone or two turns clockwise.


Trouble Recovery

42

6. Give a strong pull straight out to crank theengine. Repeat if necessary.

EMU29760

Treatment of submerged motorIf the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immediate-ly.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to minimize engine dam-age.EMU29771

Procedure1. Thoroughly wash away mud, salt, sea-

weed, and so on, with fresh water.

2. Remove the spark plugs and face thespark plug holes downward to allow anywater, mud, or contaminants to drain.

3. Drain the fuel from the carburetor, fuel fil-ter, and fuel line.

4. Feed fogging oil or engine oil through thecarburetor(s) and spark plug holes whilecranking with the manual starter or emer-gency starter rope.

5. Take the outboard motor to a Yamahadealer as soon as possible.

CAUTION:ECM00400

Do not attempt to run the outboard motoruntil it has been completely inspected.

ZMU01909

ZMU01910

ZMU01911


YAMAHA MOTOR CO., LTD.

Printed on recycled paperPrinted in JapanApril 2007–0.4 × 1 CR


Yamaha 2C HP

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